JP4442587B2 - Stator for rotating electric machine and method for manufacturing the same - Google Patents

Description

  The present invention relates to a stator for a rotating electrical machine.

  2. Description of the Related Art Conventionally, there has been known a technique for increasing the output of a rotating electrical machine by regularly arranging substantially U-shaped electric conductors to increase the space factor of the electric conductors in the stator slots (for example, patents). Reference 1). In the stator described in Patent Document 1, a process of bending a U-shaped electric conductor inserted into a slot of a stator winding by using a twisting device is disclosed.

By the way, when the electric conductor used for the stator of the conventional rotating electric machine described above is bent by a twisting device, each electric conductor is bent with the slot peripheral portion on the end face side of the stator core as a fulcrum. . Therefore, the insulating coating of the electric conductor that contacts the peripheral edge of the slot may be damaged, and there is a possibility that sufficient electric insulation cannot be ensured between the stator core and the electric conductor.
Japanese Patent No. 319638

  The present invention has been made in view of the above problems, and a main object of the present invention is to provide a stator for a rotating electrical machine capable of ensuring electrical insulation between a stator core and a stator winding, and a method for manufacturing the same. Is.

  Hereinafter, means and the like effective for solving the above-described problems will be described while showing functions and effects as necessary.

In the first aspect of the present invention, a cylindrical stator core in which a plurality of teeth are arranged in the circumferential direction and a plurality of slots are formed between adjacent teeth, and an electric conductor having an insulating coating layer on the outer periphery are provided. A stator winding formed and housed in the slot and formed by bending a part protruding from the end face of the stator core in the circumferential direction; and disposed on the teeth at the end face of the stator core A stator of a rotating electrical machine including an insulating member, wherein the stator core has a small circumferential width at a portion corresponding to the teeth on an axial end surface side and a protruding portion protruding in the axial direction has, the insulating member has a hole portion to be fitted to the projecting portion, the hole portion by positioning the insulating member by fitting the protrusion, the insulation member, wherein the scan It is characterized by providing to project to the side to narrow the opening of Tsu and.

According to this, the insulating member protrudes to the side that narrows the opening of the slot. For this reason, when the stator is placed under vibration, the stator winding contacts the insulating member, not the peripheral edge of the slot. As a result, even if the stator winding comes into contact with the insulating member and the insulating coating layer of the stator winding is damaged, the insulating coating layer is damaged because the counterpart to which the stator winding contacts is an insulating member. It is possible to prevent dielectric breakdown from occurring from the parts that have been subjected to this.
Further, the protruding portion of the fixed iron core is fitted into the hole of the insulating member. Thereby, positioning of an insulating member becomes easy and position shift can be suppressed. In addition, since the insulating member has a portion that overlaps with the axial direction of the fixed iron core, it is possible to ensure the axial length facing the stator winding while suppressing an increase in the physique. As a result, the output of the rotating electrical machine can be improved.

  The invention according to claim 2 is characterized in that a circumferential corner of the insulating member disposed on the tooth is a curved surface. According to this, even if the stator winding is in contact with the insulating member, since the contact portion on the insulating member side is a curved surface, damage to the insulating coating layer of the stator winding can be suppressed.

  The invention according to claim 3 is characterized in that the insulating member is made of resin. By forming with resin, the insulating member can be easily molded. Moreover, favorable insulation can be ensured by using a resin.

  According to a fourth aspect of the present invention, the insulating member is provided with a protruding portion that engages with a non-accommodating portion of the stator winding in the slot. This facilitates positioning when the insulating member is arranged on the end face of the stator core, and can prevent displacement after the arrangement.

  In addition, the insulating member disposed on the adjacent teeth is formed by connecting the inner peripheral side or the outer diameter side thereof, and the protruding portion that engages the slot at the inner peripheral side or the outer diameter side connecting portion. Can also be provided.

  The invention according to claim 5 is characterized in that the insulating member is provided so as to have a portion overlapping the axial direction of the teeth. This facilitates positioning when the insulating member is arranged on the end face of the stator core, and can prevent displacement after the arrangement. Moreover, by setting it as this structure, the axial direction length facing the stator winding | coil in an insulating member is securable. As a result, the insulation in the vicinity of the end portion in the axial direction in the slot can be further improved. Furthermore, the height of the stator core can be ensured by ensuring that the insulating member overlaps the axial direction of the teeth while ensuring the axial length of the insulating member facing the stator winding. As a result, it is possible to ensure the output of the rotating electrical machine.

Incidentally, it provided with a space extending and radially surrounded by the insulating member may Rukoto are opened the radial end portion of the space. With this configuration, when a stator winding is formed by bending a portion protruding from the end face of the stator core in the circumferential direction, a support member or the like is inserted into the space from the radial opening. be able to. Thereby, a deformation | transformation of the insulation member by applying a strong force to an insulation member at the time of bending can be suppressed. Further, after the bending is completed, the stator can be reduced in weight by extracting the support member and the like.

The invention according to claim 6 is characterized in that the insulating coating layer is formed by providing an enamel layer on the outer periphery of the electric conductor and providing an extrusion coating resin layer on the outer periphery of the enamel layer. With this configuration, it is easy to form a thick insulating coating.

The invention according to claim 7 is characterized in that a plurality of conductor segments are used as the electrical conductors, and ends of the plurality of conductor segments are joined together to form the stator winding. Thereby, since it becomes easy to arrange | position the electrical conductor which forms a stator coil | winding in a slot, manufacture of a stator coil | operator becomes easy.

The invention according to claim 8 is characterized in that a cross-sectional shape of the conductor segment in the slot is a substantially rectangular shape along the slot shape. Thereby, it becomes easy to increase the space factor of the electric conductor in the slot.

The invention according to claim 9 is characterized in that the stator according to any one of claims 1 to 8 is applied to a rotating electrical machine mounted on a vehicle. When the rotating electrical machine is mounted on a vehicle, the stator windings easily come into contact with the peripheral portion of the slot or the like due to vehicle vibration or the like. In this regard, by employing the stator of the present invention, it is possible to suppress dielectric breakdown even in a severe environment such as a vehicle.

Incidentally, a plurality of circumferential teeth are arranged in a plurality of conductor segments having a plurality of slots between the teeth and the cylindrical stator core formed, formed by an electrical conductor having an insulating coating layer on the outer periphery of the adjacent A stator winding comprising: a stator winding comprising: and an insulating member provided on the teeth on the end face of the stator core so as to protrude toward the side narrowing the opening of the slot. An insulating member disposing step of disposing the insulating member on an end surface of the stator core; a segment inserting step of inserting the conductor segment into the slot; and the conductor segment protruding from an end of the slot A bending process of bending the member in the circumferential direction with the member as a fulcrum, and the ends of the segments bent by the bending process are connected to each other. Better to have a bonding step of.

  According to this, the conductor segment is bent with the insulating member as a fulcrum. For this reason, even if the insulation coating layer of the stator winding is damaged during the bending process, since the counterpart to which the stator winding contacts is an insulating member, dielectric breakdown starts from the damaged portion of the insulation coating layer. Can be prevented from happening.

Further, the has a space where the insulating surrounded by members to and open ends extending radially, a support member inserting step of inserting the support member into said space from said opening, said support member from said space and a support member extraction step of extracting, said bending step, carries out after the support member inserting step, said supporting member extraction step may be performed after the bending step.

  The bending process is performed with the support member inserted into the space. For this reason, when bending a conductor segment, it can suppress that an insulating member deform | transforms by applying a strong force to the insulating member which has the space extended in radial direction. Moreover, after a bending process is complete | finished, a stator can be reduced in weight by extracting a supporting member from the inside of space.

[First embodiment]
Hereinafter, an embodiment in which the rotating electric machine of the present invention is embodied as a motor generator (MG) 10 for driving a vehicle will be described.

  First, the configuration of the MG 10 of this embodiment will be described. FIG. 1 is a cross-sectional view showing the overall structure of the MG 10 of the present embodiment. FIG. 2 is a circuit diagram of the MG 10. As shown in FIG. 1, the MG 10 of this embodiment includes a housing 11, a rotor 20, and a stator 30.

  The rotor 20 includes a rotating shaft 21, a rotor iron core 22, and a permanent magnet 23. The rotor core 22 is fixed to the rotating shaft 21. The rotating shaft 21 is rotatably supported by the housing 11 through a pair of bearings 12 and 13. A plurality of permanent magnets 23 are embedded in the circumferential direction of the rotor core 22 at a predetermined pitch, and are magnetized so that the polarities of the permanent magnets 23 are alternately different in the circumferential direction. The structure of the rotor 20 can be replaced with various known types such as a winding field type in which a field winding is wound around a Landel pole core.

  The stator 30 is disposed on the radially outer side of the rotor 20. The stator 30 includes a stator core 31 and a stator winding 32. The stator core 31 is cylindrical and is fixed to the inner peripheral surface of the peripheral wall of the housing 11. The stator winding 32 is wound around each slot of the stator core 31. Further, the first coil end portion 32a of the stator winding 32 protrudes in the direction along the rotary shaft 21 from one axial end surface of the stator core 31, and the stator winding from the other axial end surface. 32 second coil end portions 32 b protrude in the direction along the rotation shaft 21.

  As shown in FIG. 2, the stator winding 32 is formed by Y-connecting a U-phase coil 32U, a V-phase coil 32V, and a W-phase coil 32W. The U-phase coil 32U is formed by connecting the circumferential coils U1, U2, U3, U4 in series. Similarly, the V-phase coil 32V is formed by connecting the winding coils V1, V2, V3, and V4 in series. Similarly, the W-phase coil 32W is formed by connecting the winding coils W1, W2, W3, and W4 in series.

  An inverter 41 is connected between the battery 40 and the external lead terminals 320U, 320V, and 320W of each phase coil. The inverter 41 is composed of six power elements 42.

  When the vehicle is driven, the power element 42 is appropriately switched according to an instruction from a controller (not shown), and a three-phase AC voltage is applied from the battery 40 to the stator winding 32 via the inverter 41. The rotor 20 rotates by this applied voltage. A rotating shaft 21 of the rotor 20 is directly connected to an engine crankshaft (not shown) or connected via a clutch, gear, or the like. In the case of direct connection, the engine is started by the rotation of the rotating shaft 21 of the rotor 20. On the other hand, during charging, current flows from the stator winding 32 to the battery 40 due to rotation of the crankshaft and the rotating shaft 21 of the rotor 20. The battery 40 is charged by this current.

  Next, details of the stator 30 will be described.

  As shown in FIG. 3, the stator core 31 is formed by laminating a large number of ring-shaped core sheets 36. Concave portions 37 corresponding to the slots 35 are formed at equal intervals on the inner peripheral side of the core sheet 36. The core sheet 36 is formed by punching a thin steel plate using a press die. In addition, 96 recesses 37 corresponding to the slots 35 are formed so as to accommodate the three-phase stator windings 32 in the slots 35 corresponding to the number of magnetic poles of the rotor 20. By laminating a large number of the core sheets 36, 96 slots 35 in which the multiphase stator windings 32 are accommodated in the circumferential direction are formed, and 96 teeth 34 are formed between the adjacent slots 35. Is done.

  FIG. 4 is a perspective view showing a schematic shape of the basic segment 33 constituting the stator winding 32. As shown in FIG. 4, the stator winding 32 is formed by connecting segments 33 in which an electric conductor having a substantially rectangular cross section (flat cross section) and having a constant thickness is formed in a substantially U shape. The basic segment 33 includes a large segment 331 and a small segment 332.

  The large segment 331 includes an inner diameter side accommodated portion 331a, an outer diameter side accommodated portion 331b, a turn portion 331c, an inner diameter side open end portion 331d, and an outer diameter side open end portion 331e. The inner diameter side accommodated portions 331a and 332a and the outer diameter side accommodated portions 331b and 332b are accommodated in two slots 35 that are separated from each other by a predetermined magnetic pole pitch (in this embodiment, 12 slots). The inner diameter side accommodated portion 331 a of the large segment 331 is disposed on the innermost diameter side in the slot 35, and the outer diameter side accommodated portion 331 b is disposed on the outermost diameter side in the slot 35. The turn part 331 c connects one end of the inner diameter side accommodated part 331 a and one end of the outer diameter side accommodated part 331 b outside the slot 35. The inner diameter side open end 331d extends out of the slot 35 from the other end of the inner diameter side accommodated part 331a. Similarly, the outer diameter side open end 331e extends out of the slot 35 from the other end of the outer diameter side accommodated part 331b.

  Similarly to the large segment 331, the small segment 332 also has an inner diameter side accommodated portion 332a, an outer diameter side accommodated portion 332b, a turn portion 332c, an inner diameter side open end portion 331d, and an outer diameter side open end portion 332e. . The small segment 332 is disposed so as to be surrounded by the large segment 331. The inner diameter side accommodated portion 332a and the outer diameter side accommodated portion 332b are accommodated in two slots that are separated by a predetermined magnetic pole pitch. The inner diameter side accommodated portion 332a is disposed adjacent to the outer diameter side of the inner diameter side accommodated portion 331a in the slot 35, and the outer diameter side accommodated portion 332b is the inner diameter side of the outer diameter side accommodated portion 331b in the slot 35. It is arranged adjacent to. The turn part 332c connects one end of the inner diameter side accommodated part 332a and one end of the outer diameter side accommodated part 332b outside the slot. The inner diameter side open end 332d extends out of the slot from the other end of the inner diameter side accommodated part 332a. Similarly, the outer diameter side open end 332e extends out of the slot from the other end of the outer diameter side accommodated part 332b.

  FIG. 5 shows a cross-sectional view of the large segment 331. As shown in FIG. 5, the segment 331 is formed by providing an insulating coating 39 on the outer periphery of a conductor portion 33a made of an electric conductor. In this embodiment, an enamel layer 39a is provided on the outer periphery of the conductor portion 33a with a film thickness of about 40 μm, and a polyphenylene sulfide (PPS) resin layer 39b as an extrusion coating resin layer is provided on the outer periphery of the enamel layer 39a with a film thickness of about 70 μm. It has been. The small segment 332 has the same configuration.

  FIG. 6 is a partially developed view of a cross section perpendicular to the axial direction of the stator 30. As described above, the stator winding 32 is formed by connecting the ends of the plurality of basic segments 33. The slots 35 of the stator core 31 accommodate the receiving portions 331a, 331b, 332a, 332b of even-numbered (four in this embodiment) segments 331, 332, respectively. The accommodated portions 331a, 331b, 332a, 332b of the four segments 331, 332 in one slot 35 are arranged from the inner side to the inner end layer X1, the inner middle layer X2, the outer middle layer X3, the outer side in the radial direction of the stator core 31. They are arranged in a line in the order of the end layer X4.

  In this embodiment, an insulator-less configuration in which a sheet-like insulator such as insulating paper is not disposed between the segments 331 and 332 in the slot 35 and the inner wall surface of the slot.

  As described above, the accommodated portions 331a, 331b, 332a, and 332b arranged in each slot 35 are accommodated in other slots 35 that are separated by a predetermined magnetic pole pitch (12 slots in this embodiment). It forms a pair with the parts 331a, 331b, 332a, 332b. In particular, in order to secure and arrange the gaps between the plurality of segments 331 and 332 in the first and second coil end portions 32a and 32b, the received portions 331a and 331a of a predetermined layer in one slot 35 are arranged. 331b, 332a, and 332b are paired with the receiving portions 331a, 331b, 332a, and 332b of other layers in the other slots 35 that are separated by a predetermined magnetic pole pitch.

  For example, as shown in FIG. 6, the accommodated portion 331a of the inner end layer X1 in one slot 35 in the rotating coil U1 is another slot 35 that is one magnetic pole pitch away in the clockwise direction of the stator core 31. It is paired with the accommodated portion 331b of the inner outer end layer X4. Similarly, the accommodated portion 332a of the inner middle layer X2 in one slot 35 in the winding coil U1 is accommodated in the outer middle layer X3 in the other slot 35 that is one magnetic pole pitch away in the clockwise direction of the stator core 31. It is paired with the portion 332b.

  The paired receiving portions 331a, 331b, 332a, 332b are connected by a continuous line (turn portions 331c, 332c) on the first coil end portion 32a side of the stator core 31. Therefore, on the first coil end portion 32a side of the stator core 31, the turn portion 332c that connects the accommodated portion 332b of the inner middle layer X2 and the accommodated portion 332b of the outer middle layer X3 is accommodated in the inner end layer X1. The turn part 331c which connects the part 331a and the to-be-accommodated part 331b of the outer end layer X4 surrounds.

  On the other hand, the accommodation portion 332a of the inner middle layer X2 in one slot 35 in the winding coil U1 is covered by the inner end layer X1 in another slot 35 that is one magnetic pole pitch away in the clockwise direction of the stator core 31. It is also paired with the accommodating portion 331a ′. Similarly, the accommodated portion 331b ′ of the outer end layer X4 in one slot 35 in the winding coil U1 is the outer middle layer X3 in another slot 35 that is one magnetic pole pitch away in the clockwise direction of the stator core 31. It is paired with the accommodated portion 332b.

  Then, on the second coil end portion 32b side of the stator core 31, open end portions 332d, 331d ′, 331e ′, which extend outside the slot 35 from these accommodated portions 332a, 331a ′, 331b ′, 332b, The ends of 332e are joined by welding or the like. Therefore, on the second coil end portion 32b side of the stator core 31, a joint portion connecting the electric conductor of the inner end layer X1 and the electric conductor of the inner middle layer X2, and the electric conductor of the outer middle layer X3 and the outer end layer X4. Are joined in the radial direction.

  The basic segments 33 are regularly arranged in the slots 35 to form the respective winding coils that make two rounds around the stator core 31. In addition, the turn part which connects the 1st round and the 2nd round is comprised by the deformed segment from which the basic segment 33 differs in shape. In addition, the segment that connects the respective winding coils and the segment that forms the lead wire of the stator winding 32 are also formed by deformed segments.

  An end plate 38 is disposed on the end surface of the stator core 31 on the second coil end portion 32b side. 7A and 7B are views partially showing a state in which the end plate 38 is disposed on the end face of the stator core 31. FIG. 7A is a plan view and FIG. 7B is a side view on the inner peripheral side. FIG. 8 is a partial cross-sectional view on the second coil end 32b side.

  As shown in FIG. 7, the end plate 38 has a ring shape and is made of resin. The end plates 38 are formed with equal numbers of holes 38a as the slots 35 of the stator core 31 at equal intervals. The radial and circumferential lengths of the holes 38a are slightly shorter than the radial and circumferential lengths of the slots 35. In addition, the peripheral portion 38b of the hole 38a on the upper surface side of the end plate 38 (the side not in contact with the end surface of the stator core 31) has a curved surface with its corners dropped.

  On the inner peripheral side of the lower surface of the end plate 38, the same number of protrusions 38c as the slots 35 are formed. The protrusion 38 c is formed at a position corresponding to the center in the circumferential direction of each hole 38 a and has a width that fits in the axial end of the inner diameter side opening 35 a of the slot 35. Positioning when the end plate 38 is arranged on the end surface of the stator core 31 is performed by the projection 38c.

  By positioning the projection 38c and the inner diameter side opening 35a and arranging the end plate 38 on the end surface of the stator core 31, the hole 38a is arranged so as to overlap the slot 35 as shown in FIG. It is like that.

  As described above, the circumferential length of the hole 38 a formed in the end plate 38 is slightly shorter than the circumferential length of the slot 35. For this reason, as shown in FIG. 8, the inner wall portion 38 d in the circumferential direction of the hole 38 a protrudes from the peripheral edge portion 35 b of the slot 35 toward the slot 35. In other words, the inner wall portion 38d in the circumferential direction of the hole 38a narrows the opening of the slot 35 on the axial direction side. The segment 33 protruding from the slot 35 is bent by being twisted in the circumferential direction with the peripheral portion 38b of the hole 38a formed in the end plate 38 as a fulcrum.

  Next, the manufacturing process of the stator 30 will be described below.

  (End plate arrangement | positioning process) First, the end plate 38 is arrange | positioned at the one end surface side of the axial direction of the stator core 31 formed by laminating | stacking the core sheet | seat 36. FIG.

  (Insertion process) As shown in FIG. 9, the basic segment 33 is placed on the other end side in the axial direction of the stator core 31 in a state where the turn part 332c of the small segment 332 is aligned with the turn part 331c of the large segment 331. Insert from the end plate 38 side. At that time, one accommodating portion 331a of the large segment 331 is in the inner end layer X1 of one slot 35 of the stator core 31, one accommodating portion 332a of the small segment 332 is in the inner middle layer X2 of one slot 35, and The other accommodating portion 331b of the large segment 331 is also connected to the outer end layer X4 of the other slot 35 that is one magnetic pole pitch clockwise from one slot 35 of the stator core 31, and the other accommodating portion 332b of the small segment 332 is also disposed. The other slot 35 is inserted into the outer middle layer X3.

  As a result, as shown in FIG. 6, in the one slot 35, the accommodating portions 331a, 332a, 332b ′, 331b ′ described above are arranged in a row from the inner end layer X1 side. Here, the accommodating portions 332b ′ and 331b ′ are accommodating portions of the large and small segments 331 and 332 that are paired with the accommodating portions in the other slots 35 that are shifted by one magnetic pole pitch. Note that the order of the end plate arranging step and the inserting step can be reversed.

  (Bending process) After insertion of the segment 33, the outer diameter side located on the end layer side in the vicinity of the peripheral portion 38b of the hole 38a of the end plate 38 on the second coil end portion 32b side (the side where the end plate 38 is present) The open end portions 331d and 331e on the inner diameter side are twisted and bent in the direction in which the large segment 331 opens by a half magnetic pole pitch (in this embodiment, six slots). The open end portions 332d and 332e on the outer diameter side and the inner diameter side located in the middle layer are twisted and bent by a half magnetic pole pitch in the direction in which the small segment 332 is closed. The segment 33 is bent with the curved portion of the peripheral edge 38b of the hole 38a as a fulcrum. As a result, in the second coil end portion 32b, the open end portions 331d, 331e, 332d, 332e of the segments 331, 332 adjacent in the radial direction are inclined in the opposite direction in the circumferential direction. The above operation is performed for the segments 33 of all the slots 35.

  (Jointing Step) Then, in the second coil end portion 32b, the open end 331e ′ of the outer end layer X4 and the open end 332e of the outer middle layer X3, and the open end 332d of the inner middle layer X2 and the inner end layer X1 are opened. The end portion 331d ′ is joined to obtain electrical continuity by means of welding, ultrasonic welding, arc welding, brazing, or the like, and the stator 30 is obtained.

  Next, the detail of the bending process mentioned above is demonstrated.

  FIG. 10 is a cross-sectional view of a twisting device that twists the open end 331d and the like of the segment 33 in the bending step. 10 includes a workpiece receiver 51, a clamper 52, a workpiece presser 53, a twist shaping unit 54, a lifting shaft 54a, rotational drive mechanisms 541a, 542a, 543a, and 544a, a lifting drive mechanism 54b, A controller 55 is provided.

  The workpiece receiver 51 is for receiving and fixing the outer periphery of the stator core 31. The clamper 52 is for holding the stator core 31 by restricting the radial movement of the stator core 31. The work holder 53 is for preventing the stator core 31 from being lifted.

  The twist shaping portion 54 is for twisting the open end portion 331d of the segment 33 protruding from the end portion of the stator core 31, and can be rotationally driven in the circumferential direction by the rotation drive mechanisms 541a, 542a, 543a, 544a. It has become. The elevating shaft 54a is for driving the twist shaping portion 54 in the axial direction, and is movable in the axial direction by the elevating drive mechanism 54b. The controller 55 is for controlling the operations of the rotation drive mechanisms 541a, 542a, 543a, 544a and the elevation drive mechanism 54b.

  FIG. 11 is a plan view of the twist shaping unit 54. In the twist shaping section 54, four cylindrical twist jigs 541, 542, 543, and 544 arranged concentrically are arranged with their front end surfaces aligned. Each of the twisting jigs 541, 542, 543, and 544 can be independently rotated in the circumferential direction by rotation driving mechanisms 541a, 542a, 543a, and 544a. The four twisting jigs 541, 542, 543, and 544 can be lifted and lowered simultaneously with the rotation in the circumferential direction by raising and lowering the lifting shaft 54a by the lifting drive mechanism 54b.

  As shown in FIG. 11, inserted portions 541b, 542b, 543b, and 544b to which the end portions of the segments 33 are inserted and held are provided on the tip surfaces of the twisting jigs 541, 542, 543, and 544. Yes. These inserted portions 541b, 542b, 543b, and 544b are formed side by side in the circumferential direction of the respective twisting jigs 541, 542, 543, and 544, as many as the slots 35 formed in the stator core 31.

  Next, the operation of the twisting device 50 will be described. A stator core 31 having an end plate disposed on one end face and a segment 33 inserted into the slot 35 is set on the work receiver 51. The outer periphery of the stator core 31 is fixed by the clamper 52. Thereafter, the upper part of the stator core 31 and the turn part 331c of the large segment 331 are pressed by the work holder 53, so that the vertical movement of the stator core 31 and the segment 33 is restricted.

  Thereafter, the twist shaping portion 54 is raised by the lifting shaft 54a, and the open end portion 331d of the segment 33 and the like are inserted into the inserted portions 541b, 542b, 543b, and 544b formed in the respective twisting jigs 541, 542, 543, and 544. Inserted.

  12 and 13 are diagrams schematically showing a state before and after the segment 33 is twisted by the twisting jig 541 and the like, and a cross section along the circumferential direction of the twisting jig 541 and the like is shown. As shown in FIG. 12, only the portion that is used as a joint portion in the subsequent joining step, such as the open end portion 331d of the segment 33, is inserted into the inserted portion 541b or the like.

  Next, the twist shaping unit 54 is raised simultaneously with the rotation by the rotation drive mechanisms 541a to 544a and the elevation drive mechanism 54b. Note that the twist shaping unit 54 is raised simultaneously for all of the twisting jigs 541 to 544. As for the rotation of the twist shaping unit 54, the twist jigs 541 and 543 shown in FIG. 11 rotate by the same angle in the clockwise direction, and the twist jigs 542 and 544 rotate by the same angle in the counterclockwise direction. The rotation angle of the twisting jig 541 or the like is an angle corresponding to the half magnetic pole pitch (for 6 slots) of the stator 30.

  Thereby, the segment 33 is twisted in the circumferential direction. As shown in FIG. 8, the inner wall portion 38 d in the circumferential direction in the hole 38 a of the end plate 38 protrudes from the peripheral edge portion 35 b of the slot 35 toward the slot 35. For this reason, when the segment 33 is twisted in the circumferential direction, the segment 33 is bent with the curved portion of the peripheral edge 38b of the hole 38a of the end plate 38 as a fulcrum. As a result, as shown in FIG. 13, on the second coil end 32b side, the segments 331 and 332 adjacent in the radial direction are inclined in the opposite direction in the circumferential direction. The ends of the paired segments 331 and 332 in the other slot 35 separated by one magnetic pole pitch are arranged adjacent to each other in the radial direction.

  Thereafter, the twist shaping unit 54 is lowered together with the lifting shaft 54a by the lifting drive mechanism 54b, the restraint by the workpiece receiver 51 and the clamper 52 is released, and the stator 30 before the joining process is taken out.

  According to the embodiment described above in detail, the following excellent effects can be obtained.

  In the present embodiment, the inner wall portion 38 d in the circumferential direction of the hole 38 a provided in the resin end plate 38 projects from the peripheral edge portion 35 b of the slot 35 toward the slot 35. For this reason, when the MG 10 is placed under vibration or the like, the segment 33 contacts the inner wall portion 38d in the circumferential direction of the hole 38a in the end plate 38, not the peripheral portion 35b of the slot 35. Since the end plate 38 is made of resin, damage to the insulating coating 39 of the segment 33 can be suppressed as compared with the case where the end plate 38 is in contact with the slot 35 of the stator core 31 formed by stacking steel plates. In particular, in this embodiment, since the peripheral portion 38b of the hole 38a of the end plate 38 has a curved shape, damage to the insulating film 39 of the segment 33 due to contact between the segment 33 and the peripheral portion 38b of the hole 38a is further suppressed. can do.

  In the present embodiment, when the open end 331d of the segment 33 inserted into the slot 35 is twisted and bent in the circumferential direction, the peripheral portion 38b of the hole 38a in the end plate 38 serves as a fulcrum. The end plate 38 is made of resin, and the peripheral edge 38b of the hole 38a is curved. Therefore, when the segment 33 is twisted and bent with the peripheral edge 38b of the hole 38a as a fulcrum, the insulating coating 39 provided on the segment 33 is prevented from being damaged.

  In the present embodiment, the end plate 38 is formed of a resin that is an insulating material. Even if the segment 33 comes into contact with the peripheral edge 38b of the hole 38a of the end plate 38 and the insulating coating 39 of the segment 33 is damaged, the other end of the contact with the segment 33 is an insulating member, so the insulating coating 39 is damaged. It is possible to prevent dielectric breakdown from occurring from the received part.

  In the present embodiment, the end plate 38 is made of resin. By forming the resin, the end plate 38 can be easily formed. Moreover, favorable insulation can be ensured by using a resin.

  In the present embodiment, the end plate 38 has a ring shape and has a protrusion 38c on the inner peripheral side lower surface. The protrusion 38 c is formed with a width that fits into the axial end of the inner diameter side opening 35 a of the slot 35. As a result, positioning of the end plate 38 with respect to the stator core 31 is facilitated and displacement after the end plate 38 is disposed can be suppressed.

  In this embodiment, the thickness of the insulating coating 39 applied to the segment 33 is about 110 μm including the enamel layer 39a and the PPS layer 39b. As a result, the insulation of the segment 33 can be enhanced. In addition, since a predetermined distance can be secured between the slot 35 and the inner wall surface, it is possible to suppress the occurrence of corona discharge.

  In this embodiment, the insulating coating 39 is formed by the enamel layer 39a and the PPS resin layer 39b as the extrusion coating resin layer. Although it is not easy to make a thick film only by the enamel layer 39a, it is easy to make a thick film by combining the enamel layer 39a and the PPS resin layer 39b to form the double insulating film 39.

  In the present embodiment, the stator winding 32 is formed by inserting a substantially U-shaped segment 33 into the slot 35 and then joining the ends thereof. By making the electric conductor forming the stator winding 32 into a segment shape, it becomes easy to arrange the segment 33 in the slot 35. Thereby, manufacture of the stator winding | coil 32 becomes easy. Further, the segment 33 has a substantially rectangular cross section, and follows the shape of the slot 35. Thereby, it becomes easy to increase the space factor of the segment 33 (electrical conductor) in the slot 35.

  In addition, by adopting the configuration of the present embodiment, it is possible to effectively suppress dielectric breakdown even when the vehicle is mounted, in which vibration or the like may frequently occur. Further, by realizing a high space factor of the electric conductor in the slot as in the present embodiment, it is possible to realize a high output MG 10 suitable for driving a vehicle.

[Second Embodiment]
Next, a second embodiment of the present invention will be described with reference to the drawings. In addition, about the structure same as 1st embodiment, the code | symbol same as 1st embodiment is attached | subjected and description is abbreviate | omitted.

  FIG. 14 is a partial cross-sectional view on the second coil end 32b side in the second embodiment. Also in this embodiment, the stator core 31 is formed by stacking the core sheets 36. And several sheets from the end surface side by the side of the 2nd coil end 32b use the core sheet | seat 36 in which the circumferential direction width | variety of the part corresponding to the teeth 34 became small. As a result, the teeth 34 on the second coil end 32b side are formed with protruding portions 34a protruding in the axial direction. Further, the axial length of the stator core 31 is longer than that of the stator core 31 of the first embodiment by the amount of the protruding portion 34a.

  Also in the present embodiment, the end plate 138 is disposed on the second coil end 32 b side of the stator core 31. Similarly to the first embodiment, the end plate 138 of the present embodiment is formed in a ring shape with resin, and the thickness is the same as that of the first embodiment. Further, the point that the peripheral edge 138b of the hole 138a is curved and the inner wall 138d in the circumferential direction of the hole 138a protrudes toward the slot 35 from the peripheral edge 35b of the slot 35 are the same as in the first embodiment. It is.

  In the present embodiment, a hole 138 c is formed on the lower surface side of the end plate 138. And this hole part 138c can cover the axial direction end surface of the teeth 34 by the protrusion part 34a of the teeth 34 being engage | inserted. The end plate 138 is positioned by the hole portion 138c and the protruding portion 34a, and the end plate 138 is disposed on the end surface of the stator core 31, so that the hole 138a is disposed so as to overlap the slot 35. Yes.

  Also in this embodiment, as in the first embodiment, it is possible to ensure insulation between the stator core 31 and the stator winding 32.

  In the present embodiment, the protrusion 34 a of the tooth 34 is fitted in the hole 138 c formed in the end plate 138. This facilitates positioning of the end plate 138 and suppresses displacement. In addition, since the end plate 138 has a portion that overlaps with the axial direction of the teeth 34, the axial length facing the stator winding 32 can be secured. As a result, it is possible to further improve the insulation in the vicinity of the end portion in the axial direction in the slot 35. Furthermore, by inserting the protrusions 34a into the holes 138c formed in the end plate 138 having the same thickness as that of the first embodiment, it is possible to increase the number of stacked core sheets 36 while suppressing an increase in physique. As a result. With the same physique as the first embodiment, the output of the MG 10 can be improved.

[Third embodiment]
Next, a third embodiment of the present invention will be described with reference to the drawings. In addition, about the structure same as 1st embodiment, the code | symbol same as 1st embodiment is attached | subjected and description is abbreviate | omitted. FIG. 15 is a partial cross-sectional view on the second coil end 32b side in the third embodiment. FIG. 16 is a plan view partially showing a state in which the end plate 238 is disposed on the end face of the stator core 31.

  Also in the present embodiment, the end plate 238 is disposed on the second coil end 32 b side of the stator core 31. Similarly to the first embodiment, the end plate 238 of the present embodiment is also formed of a resin in a ring shape. Moreover, the point which the inner wall part 238d of the circumferential direction of the hole 238a protrudes in the slot 35 side rather than the peripheral part 35b of the slot 35 is the same as that of 1st embodiment.

  As shown in FIG. 15, the upper surface portion 238e of the end plate 238 connecting the inner wall portions 238d in the circumferential direction of the adjacent holes 238a is formed so that the cross section perpendicular to the radial direction has a substantially arc shape. As shown in FIGS. 15 and 16, a groove portion 238 c extending in the radial direction is formed on the lower surface side of the end plate 238. The groove 238c is formed so that the width in the circumferential direction becomes wider from the inner diameter side toward the outer diameter side, and the thickness of the inner wall part 238d in the circumferential direction of the hole 238a is made constant. A space extending in the radial direction is formed between the end plate 238 and the tooth 34 by the groove portion 238c. The groove 238c is formed with an outer diameter side opening 238f and an inner diameter side opening 238g at the outer diameter side and inner diameter side ends, respectively. A metal support jig 239 can be inserted from the outer diameter side opening 238f.

  When the stator 30 is manufactured using the end plate 238 of the present embodiment, the bending process is performed in a state where the support jig 239 corresponding to the shape of the groove 238c is inserted into the groove 238c from the outer diameter side opening 238f. I do. And after a bending process is complete | finished, the support jig | tool 239 is extracted from the groove part 238c.

  The end plate 238 may be disposed on the end surface of the stator core 31 with the support jig 239 set in the groove 238c, or after the end plate 238 is disposed on the end surface of the stator core 31. The support jig 239 may be inserted into the groove 238c before the bending step. Further, the support jig 239 may be extracted either immediately after the bending process or after the joining process.

  Also in this embodiment, as in the first embodiment, it is possible to ensure insulation between the stator core 31 and the stator winding 32.

  In the present embodiment, the bending step is performed in a state where the support jig 239 is inserted into the groove 238c. For this reason, when the segment 33 is bent, deformation of the end plate 238 due to a strong force applied to the end plate 238 can be suppressed. Moreover, after the bending process is completed, the stator 30 can be reduced in weight by extracting the support jig 239 from the groove 238c.

  In the present embodiment, circumferential inner wall portions 238d in adjacent holes 238a are connected in a substantially arc shape. Thereby, when the segment 33 is bent, a substantially arc-shaped portion can be used as a fulcrum, so that damage to the insulating coating 39 of the segment 33 in the bending step can be suppressed.

[Other Embodiments]
In addition, this invention is not limited to the content of description of the said embodiment, For example, you may implement as follows.

  In each of the above embodiments, the end plate 38 and the like are formed of resin, but the end plate may be formed of an insulating material (for example, ceramic) other than resin. Also by this, since the other party which the segment 33 contacts is an insulating member, it can suppress that dielectric breakdown arises from the part into which the insulating film 39 was damaged.

  In each of the above embodiments, the end plate 38 and the like are disposed only on the second coil end 32b side of the stator 30. However, the end plates 38 and the like may be disposed on both end surfaces of the stator 30.

  In the third embodiment, the groove portion 238c and the support jig 239 have a circumferential width that increases from the inner diameter side toward the outer diameter side. However, the circumferential width may be constant. According to this, it becomes possible to insert and extract the support jig 239 from the inner diameter side opening 238g.

  In the above embodiments, the number of slots 35 is 96 corresponding to the number of magnetic poles of the rotor 20. However, the number of slots 35 is not limited to 96, and can be changed according to the number of magnetic poles of the rotor 20.

  In each said embodiment, the extrusion coating resin layer provided in the outer periphery of the enamel layer 39a was formed using PPS resin. However, the extrusion-coated resin layer may be any material that can be extruded, and polypropylene (PP), polymethylpentene (PMP), and the like can also be used.

A sectional view showing the whole motor generator structure of a first embodiment. The circuit diagram of a motor generator. Explanatory drawing of the stator core formed by laminating | stacking a core sheet. The perspective view which shows the typical shape of the segment which comprises a stator winding | coil. Sectional drawing of a segment. The partial schematic cross section of a stator. (A) is a top view which shows the state which has arrange | positioned an end plate in the end surface of a stator core, (b) is a side view of an inner peripheral side. The fragmentary sectional view by the side of the 2nd coil end part. The perspective view which shows the insertion process of the segment with respect to a stator core. Sectional drawing of the twist apparatus which twists the open end part of a segment in a bending process. The top view of a twist shaping part. The figure which shows typically the state before a segment is twisted with the twist jig | tool. The figure which shows typically the state after a segment is twisted with the twist jig | tool. The fragmentary sectional view by the side of the 2nd coil end part of a second embodiment. The fragmentary sectional view by the side of the 2nd coil end part of a third embodiment. The top view which shows partially the state which has arrange | positioned the end plate to the end surface of a stator core.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 ... Motor generator (MG), 11 ... Housing, 12, 13 ... Bearing, 20 ... Rotor, 21 ... Rotating shaft, 22 ... Rotor core, 23 ... Permanent magnet, 30 ... Stator, 31 ... Stator core 31 ... stator winding, 33 ... segment, 34 ... teeth, 35 ... slot, 36 ... core sheet, 37 ... recess, 38 ... end plate, 38a ... hole, 38b ... peripheral edge, 38c ... projection, 38d ... inner wall 39 ... Insulating coating, 39a ... Enamel layer, 39b ... Polyphenylene sulfide (PPS) resin layer.

Claims (9)

A cylindrical stator core in which a plurality of teeth are arranged in the circumferential direction and a plurality of slots are formed between the adjacent teeth;
A stator winding formed by an electric conductor having an insulating coating layer on the outer periphery, housed in the slot, and formed by bending a part protruding from the end face of the stator core in the circumferential direction;
A stator of a rotating electrical machine comprising an insulating member disposed on the teeth at an end face of the stator core,
The stator core has a protruding portion that protrudes in the axial direction with a small circumferential width of the portion corresponding to the teeth on the axial end surface side,
The insulating member has a hole that is fitted into the protrusion,
A stator of a rotating electrical machine, wherein the insulating member is positioned by fitting the hole portion into the projecting portion to project the insulating member toward a side narrowing the opening of the slot.   The stator for a rotating electrical machine according to claim 1, wherein a circumferential corner portion of the insulating member disposed on the teeth is a curved surface.   The stator for a rotating electric machine according to claim 1 or 2, wherein the insulating member is made of resin.   The stator of the rotating electrical machine according to any one of claims 1 to 3, wherein the insulating member is provided with a protruding portion that engages with a non-accommodating portion of the stator winding in the slot.   The stator of the rotating electrical machine according to any one of claims 1 to 4, wherein the insulating member is provided so as to have a portion overlapping with an axial direction of the teeth. 6. The insulating coating layer according to claim 1 , wherein the insulating coating layer is formed by providing an enamel layer on the outer periphery of the electrical conductor and providing an extrusion coating resin layer on the outer periphery of the enamel layer. The stator of the described rotating electrical machine. 7. The stator winding according to claim 1 , wherein a plurality of conductor segments are used as the electric conductors, and ends of the plurality of conductor segments are joined to each other to form the stator winding . 8. Stator for rotating electric machine. The stator of the rotating electrical machine according to claim 7 , wherein a cross-sectional shape of the conductor segment in the slot is a substantially rectangular shape along the slot shape . The stator of a rotating electrical machine according to any one of claims 1 to 8, wherein the stator is applied to a rotating electrical machine mounted on a vehicle .

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